US20020147434A1 - Absorbent article, absorbent body for absorbent article, and manufacturing process therefor - Google Patents
Absorbent article, absorbent body for absorbent article, and manufacturing process therefor Download PDFInfo
- Publication number
- US20020147434A1 US20020147434A1 US10/116,836 US11683602A US2002147434A1 US 20020147434 A1 US20020147434 A1 US 20020147434A1 US 11683602 A US11683602 A US 11683602A US 2002147434 A1 US2002147434 A1 US 2002147434A1
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- US
- United States
- Prior art keywords
- nonwoven fabric
- fragments
- fibers
- absorbent body
- absorbent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/531—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having a homogeneous composition through the thickness of the pad
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/538—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by specific fibre orientation or weave
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/15577—Apparatus or processes for manufacturing
- A61F13/15617—Making absorbent pads from fibres or pulverulent material with or without treatment of the fibres
- A61F13/15626—Making fibrous pads without outer layers
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F2013/530131—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium being made in fibre but being not pulp
- A61F2013/530182—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium being made in fibre but being not pulp characterized by the connection between the fibres
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
- Y10T156/1062—Prior to assembly
Definitions
- the present invention relates to an absorbent article such as disposable diaper, pad for diaper, sanitary napkin, pet sheet and the like. More particularly, the present invention relates to an absorbent body to be used in the absorbent article and a manufacturing process therefor.
- absorbent articles are constructed to include: a liquid-permeable topsheet; a liquid-impermeable backsheet; and an absorbent body (absorbent core) interposed between the two sheets.
- the absorbent body is composed of absorbent fibers such as pulp and particulates of absorbent polymer.
- the improvement of compressive recovery (absorbency) and the improvement of shape stability are important challenge.
- Japanese Unexamined Patent Publication (Kokai) No. 2-74254 (74254/1990) discloses an absorbent body which contains 10 to 70% by weight of heat-fusible crimped fibers, 10 to 70% by weight of fluff pulp, and 5 to 50% by weight of particulates of absorbent polymer.
- the heat-fusible crimped fibers are fusion-bonded to each other to have three-dimensional network structure, thereby improving the recovery (absorbency) and shape stability of the absorbent body.
- the heat-fusible crimped fibers are thermally fusion-bonded to each other after the heat-fusible crimped fibers, the fluff pulp and the particulate absorbent polymer are mixed, the fluff pulp (not heat-fusible fibers) and the particulate absorbent polymer become an interfering factor. More specifically, fusion-bonding of the heat-fusible crimped fibers to each other in a condition where the fluff pulp (not heat-fusible fibers) and the particulate absorbent polymer are mixed therewith, requires large calorie.
- the processing temperature is simply set at a high level in order to increase the processing speed, the fusion-bonding can be done only in the surface of the absorbent body but not inside the absorbent body. As a result, sufficient shape stability can not be provided, so that the absorbent article may lose its shape after absorption of liquid. On the other hand, even if the heating rate is lowered, there is a problem of remarkable decrease in productivity, as well as it is still difficult to sufficiently heat inside of the absorbent body.
- the present invention has been worked out in view of the shortcoming in the prior art set forth above. It is therefore an object of the present invention to provide an absorbent body for use in an absorbent article, which has superior absorbency due to improved compressive recovery and superior shape stability.
- an absorbent body for use in an absorbent article, the absorbent body comprising: fragments of nonwoven fabric including heat-fusible fibers, the heat-fusible fibers being bonded to each other to have three-dimensional structure in advance of formation of the fragments; and hydrophilic fibers, the nonwoven fabric fragments and the hydrophilic fibers being blended.
- this absorbent body since the heat-fusible fibers are bonded to each other to have three-dimensional structure in advance of formation of the nonwoven fabric fragments, vacant spaces are formed inside of the absorbent body to improve the recovery after absorption of liquid. As a result, the absorbency is also improved.
- the nonwoven fabric fragments are thermally bonded to each other after blending of the nonwoven fabric fragments and the hydrophilic fibers.
- the heat-fusible fibers are bonded to each other to have three-dimensional structure in advance of formation of the nonwoven fabric fragments, the nonwoven fabric fragments can be certainly bonded to each other with relatively small calorie, thereby improving the productivity and the shape stability of the absorbent body. That is, the internal structure of the absorbent body is so stable as to maintain its original shape even after absorption of liquid.
- the nonwoven fabric fragments consist of the heat-fusible fibers. With this, bonding of the nonwoven fabric fragments can be further facilitated.
- the hydrophilic fibers are absorbent fibers having high water-absorbency. With this, the absorbency of the absorbent body can increase further.
- the absorbent body may further contain 5 to 95% by weight of particulates of superabsorbent polymer, and the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers may be from 2:8 to 8:2. With the superabsorbent polymer thus contained, the absorbency of the absorbent body can increase further. With the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers in the range from 2:8 to 8:2, on the other hand, well-balanced absorbency can be obtained. In detail, if the blending ratio of the nonwoven fabric fragments to the hydrophilic fibers is smaller than 2:8, compressive recovery may possibly decrease to lower absorbency. If the blending ratio is greater than 8:2, on the other hand, absorbency may possibly decrease since the hydrophilic fibers are not sufficiently present.
- average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm. More preferably, the average dimensions are set within a range of 5 to 15 mm. With this, it becomes possible to maintain surface smoothness of product and to prevent clogging in production line.
- an absorbent article comprising a liquid-permeable topsheet, a liquid-impermeable backsheet and an absorbent body disposed between the topsheet and the backsheet.
- the absorbent body comprises: fragments of nonwoven fabric including heat-fusible fibers, the heat-fusible fibers being bonded to each other to have three-dimensional structure in advance of formation of the fragments; and hydrophilic fibers, the nonwoven fabric fragments and the hydrophilic fibers being blended.
- the nonwoven fabric fragments are thermally bonded to each other after blending of the nonwoven fabric fragments and the hydrophilic fibers.
- the heat-fusible fibers are bonded to each other to have three-dimensional structure in advance of formation of the nonwoven fabric fragments, the nonwoven fabric fragments can be certainly bonded to each other with relatively small calorie, thereby improving the productivity and the shape stability of the absorbent article housing the absorbent body. That is, the internal structure of the absorbent article is so stable as to maintain its original shape even after absorption of liquid.
- the nonwoven fabric fragments consist of the heat-fusible fibers. With this, bonding of the nonwoven fabric fragments can be further facilitated.
- the hydrophilic fibers are absorbent fibers having high water-absorbency. With this, the absorbency of the absorbent article can increase further.
- the absorbent body may further contain 5 to 95% by weight of particulates of superabsorbent polymer, and the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers may be from 2:8 to 8:2. With the superabsorbent polymer thus contained, the absorbency of the absorbent body can increase further. With the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers in the range from 2:8 to 8:2, on the other hand, well-balanced absorbency can be obtained. In detail, if the blending ratio of the nonwoven fabric fragments to the hydrophilic fibers is smaller than 2:8, compressive recovery may possibly decrease to lower absorbency. If the blending ratio is greater than 8:2, on the other hand, absorbency may possibly decrease since the hydrophilic fibers are not sufficiently present.
- average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm. More preferably, the average dimensions are set within a range of 5 to 15 mm. With this, it becomes possible to maintain surface smoothness of product and to prevent clogging in production line.
- a process for manufacturing an absorbent body for use in an absorbent article comprising: forming nonwoven fabric in which constituent fibers are bonded to each other to have three-dimensional structure; breaking the nonwoven fabric into fragments; blending the nonwoven fabric fragments with hydrophilic fibers; and thermally fusion-bonding the nonwoven fabric fragments to each other.
- the nonwoven fabric fragments, in which the constituent fibers have been bonded to each other to have three-dimensional structure in advance of formation of the fragments are first prepared, mixed with the hydrophilic fibers, and then thermally bonded to each other.
- the nonwoven fabric fragments can be bonded to each other with relatively small calorie, thereby improving the productivity.
- the constituent fibers of the nonwoven fabric fragments have been bonded to each other to have three-dimensional structure in advance of fusion-bonding of the nonwoven fabric fragments to each other, the nonwoven fabric fragments can be certainly fusion-bonded to each other, thereby improving the shape stability of the absorbent body.
- the absorbent body may further contain 5 to 95% by weight of particulates of superabsorbent polymer, and the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers may be from 2:8 to 8:2.
- the absorbency of the absorbent body can increase further.
- the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers in the range from 2:8 to 8:2, on the other hand, well-balanced absorbency can be obtained.
- the blending ratio of the nonwoven fabric fragments to the hydrophilic fibers is smaller than 2:8, compressive recovery may possibly decrease to lower absorbency. If the blending ratio is greater than 8:2, on the other hand, absorbency may possibly decrease since the hydrophilic fibers are not sufficiently present.
- average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm. More preferably, the average dimensions are set within a range of 5 to 15 mm. With this, it becomes possible to maintain surface smoothness of product and to prevent clogging in production line.
- FIG. 1 is an enlarged sectional view, schematically showing a structure of an absorbent body according to one embodiment of the invention
- FIG. 2 is a perspective (partially cutaway) view showing a structure of an absorbent article using the absorbent body of FIG. 1;
- FIG. 3 is a sectional view taken along line A-A of FIG. 2.
- the present invention will be discussed hereinafter in detail in terms of the preferred embodiment according to the present invention with reference to the accompanying drawings.
- numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without these specific details. In other instance, well-known structures are not shown in detail in order to avoid unnecessary obscurity of the present invention.
- the absorbent body according to the present invention can be used for various kinds of absorbent article such as disposable diaper, pad for diaper, sanitary napkin, pet sheet, and the like.
- FIG. 1 shows a structure of an absorbent body 10 according to one embodiment of the present invention.
- the absorbent body 10 is to be used for an absorbent article.
- the absorbent body 10 is in sheet form and comprises: fragments 12 formed from nonwoven fabric of which constituent fibers are bonded to each other to have three-dimensional structure in advance of formation of the fragments; hydrophilic fibers 14 ; and SAP (superabsorbent polymer) 16 .
- the nonwoven fabric fragments 12 mainly contribute to improvement of shape stability of the absorbent body 10 .
- the hydrophilic fibers 14 and the SAP 16 mainly contribute to improvement of liquid absorbency.
- the nonwoven fabric fragments 12 of three-dimensional structure can be obtained by breaking the nonwoven fabric into small fragments.
- nonwoven fabric fragments 12 preferably used is thermally bonded nonwoven fabric, such as spunbonded nonwoven fabric, point bonded nonwoven fabric, meltblown nonwoven fabric, through-air bonded nonwoven fabric, or the like.
- thermally bonded nonwoven fabric such as spunbonded nonwoven fabric, point bonded nonwoven fabric, meltblown nonwoven fabric, through-air bonded nonwoven fabric, or the like.
- through-air bonded nonwoven fabric is so bulky, and therefore, it is most preferred in view of compressive recovery.
- constituent fibers forming the nonwoven fabric fragments 12 use can be made of polyolefine fibers, polyester fibers, polyamide fibers, or thick-and-thin type or side-by-side type bicomponent fibers of polyethylene/polypropylene or polyester.
- Average dimensions of the nonwoven fabric fragments 12 are preferably set within a range of 3 to 25 mm, more preferably within a range of 3 to 15 mm, for example, to 5 mm. If the average dimensions of the nonwoven fabric fragments 12 are smaller than 3 mm, the compressive recovery is decreased; if greater than 25 mm, the fragments 12 may cause clogging in production line or impair surface smoothness of products.
- the term “average dimension” as used herein refers to the average of the maximum dimension and the minimum dimension of each fibrous nonwoven fabric fragment.
- at least 80% of the fibrous nonwoven fabric fragments are preferably set within the foregoing range. That is, it is not necessary to set the average dimensions of all the fragments within the range of 3 to 25 mm.
- cutter mill method or the like can be employed as means for breaking the nonwoven fabric into the fragments 12 .
- hydrophilic fibers 14 preferably used are absorbent fibers, such as pulp, cotton, rayon, acetate, or the like.
- SAP superabsorbent polymer
- the SAP 16 may be blended into the absorbent body 10 , for example, in an amount of 5 to 95% by weight, although it is not necessarily needed for the SAP 16 to be added thereto.
- the blending ratio of the nonwoven fabric fragments 12 to the hydrophilic fibers 14 based on weight is preferably from 2:8 to 8:2. If the blending ratio is smaller than 2:8, the compressive recovery may possibly decrease to lower the absorbency. If the blending ratio is greater than 8:2, on the other hand, the absorbency may possibly decrease since the hydrophilic fibers are not sufficiently present.
- the nonwoven fabric fragments 12 are preferably blended in an amount of 20 to 80% by weight.
- the amount of the nonwoven fabric fragments 12 is set at 60 to 80%, for example.
- the amount of the nonwoven fabric fragments 12 is preferably set at 20 to 40%.
- the nonwoven fabric fragments 12 are thermally bonded to each other.
- nonwoven fabric in which constituent fibers are bonded to each other to have three-dimensional structure is first prepared. Then, the nonwoven fabric is broken into the nonwoven fabric fragments 12 . The nonwoven fabric fragments 12 are blended with the hydrophilic fibers 14 and the SAP 16 . Thereafter, the nonwoven fabric fragments 12 are thermally fusion-bonded to each other.
- fusion-bonding of the nonwoven fabric fragments 12 to each other can be performed with relatively small calorie, thereby improving the productivity.
- constituent fibers of each nonwoven fabric fragment 12 have been already bonded to each other to have three-dimensional structure in advance of fusion-bonding of the nonwoven fabric fragments 12 to each other, fusion-bonding of the nonwoven fabric fragments 12 to each other can be certainly performed, thereby improving the shape stability of the absorbent body 10 .
- FIG. 2 shows an absorbent article 20 using the foregoing absorbent body 10 , which is embodied in an open-type disposable diaper.
- the absorbent article 20 is provided with a liquid-permeable topsheet 22 and a liquid-impermeable backsheet 24 .
- water-permeable tissue papers 26 are disposed between the topsheet 22 and the absorbent body 10 and between the backsheet 24 and the absorbent body 10 .
- the topsheet 22 and the water-permeable tissue paper 26 opposed to the topsheet 22 , and the backsheet 24 and the tissue paper 26 opposed to the backsheet 24 are bonded to each other with a hot-melt adhesive or the like, respectively.
- the upper and lower tissue papers 26 opposed to the absorbent body may also be bonded to the absorbent body with a hot-melt adhesive or the like.
- the hot-melt adhesive may be applied in an open pattern selected from patterns of an array of lines, dots, spirals, an array of waves, a lattice and the like.
- bonding may be directly performed by heat seal, sonic seal or the like.
- topsheet 22 use can be made of nonwoven fabric formed from hydrophilic fibers; apertured film, or the like.
- hydrophilic fibers use can be made of thermoplastic fibers (e.g., polyolefine fibers, polyester fibers, polyamide fibers, or thick-and-thin type or side-by-side type bicomponent fibers of polyethylene/polypropylene or polyester) treated to be hydrophilic, or absorbent fibers (e.g., pulp, rayon, acetate or cotton).
- the apertured film preferably used is polyolefine film of polyethylene, polypropylene or the like.
- the backsheet 24 use can be made of polyethylene film, polypropylene film, polyester film, polyurethane film or the like.
- the backsheet is preferred to be moisture-permeable.
- the absorbent article 20 thus constructed can restore to its original shape after removal of the effect of the external force.
- the absorbent article 20 readily conforms to the body shape of the wearer and also exhibits superior followability to the body movement.
- the absorbent body 10 exhibits superior absorbency due to the hydrophilic fibers 14 and the SAP 16 blended therein.
- the nonwoven fabric fragments in which the constituent fibers have been bonded to each other to have three-dimensional structure in advance of formation of the fragments, are first prepared, mixed with the hydrophilic fibers, and then thermally bonded to each other. Therefore, the nonwoven fabric fragments can be bonded to each other with relatively small calorie, thereby improving the productivity.
- the constituent fibers of the nonwoven fabric fragments have been bonded to each other to have three-dimensional structure in advance of fusion-bonding of the nonwoven fabric fragments to each other, the nonwoven fabric fragments can be certainly fusion-bonded to each other, thereby improving the shape stability of the absorbent body.
Abstract
Disclosed is an absorbent body for use in an absorbent article. The absorbent body includes: fragments of nonwoven fabric including heat-fusible fibers, the heat-fusible fibers being bonded to each other to have three-dimensional structure in advance of formation of the fragments; and hydrophilic fibers. The nonwoven fabric fragments and the hydrophilic fibers are blended.
Description
- The present invention relates to an absorbent article such as disposable diaper, pad for diaper, sanitary napkin, pet sheet and the like. More particularly, the present invention relates to an absorbent body to be used in the absorbent article and a manufacturing process therefor.
- Generally, absorbent articles are constructed to include: a liquid-permeable topsheet; a liquid-impermeable backsheet; and an absorbent body (absorbent core) interposed between the two sheets. In many cases, the absorbent body is composed of absorbent fibers such as pulp and particulates of absorbent polymer. In case of the absorbent body for use in absorbent article, the improvement of compressive recovery (absorbency) and the improvement of shape stability are important challenge.
- Japanese Unexamined Patent Publication (Kokai) No. 2-74254 (74254/1990) discloses an absorbent body which contains 10 to 70% by weight of heat-fusible crimped fibers, 10 to 70% by weight of fluff pulp, and 5 to 50% by weight of particulates of absorbent polymer. In this absorbent body, the heat-fusible crimped fibers are fusion-bonded to each other to have three-dimensional network structure, thereby improving the recovery (absorbency) and shape stability of the absorbent body.
- However, in the invention disclosed in Japanese Unexamined Patent Publication No. 2-74254, the density of the three-dimensional framework composed of the heat-fusible fibers, the fluff pulp and the particulate absorbent polymer is high, which becomes a factor of interfering with one of basic functions in absorbent body i.e., swelling of the particulate absorbent polymer when body fluid is absorbed by the particulate polymer. In other words, there is a possibility of decreasing absorbency due to insufficient compressive recovery.
- In addition, since the heat-fusible crimped fibers are thermally fusion-bonded to each other after the heat-fusible crimped fibers, the fluff pulp and the particulate absorbent polymer are mixed, the fluff pulp (not heat-fusible fibers) and the particulate absorbent polymer become an interfering factor. More specifically, fusion-bonding of the heat-fusible crimped fibers to each other in a condition where the fluff pulp (not heat-fusible fibers) and the particulate absorbent polymer are mixed therewith, requires large calorie. Here, if the processing temperature is simply set at a high level in order to increase the processing speed, the fusion-bonding can be done only in the surface of the absorbent body but not inside the absorbent body. As a result, sufficient shape stability can not be provided, so that the absorbent article may lose its shape after absorption of liquid. On the other hand, even if the heating rate is lowered, there is a problem of remarkable decrease in productivity, as well as it is still difficult to sufficiently heat inside of the absorbent body.
- The present invention has been worked out in view of the shortcoming in the prior art set forth above. It is therefore an object of the present invention to provide an absorbent body for use in an absorbent article, which has superior absorbency due to improved compressive recovery and superior shape stability.
- It is another object of the present invention to provide an absorbent article having superior absorbency and superior shape stability.
- It is still another object of the present invention to provide a process for readily manufacturing an absorbent body for use in an absorbent article, which has superior absorbency and superior shape stability.
- According to a first aspect of the present invention, there is provided an absorbent body for use in an absorbent article, the absorbent body comprising: fragments of nonwoven fabric including heat-fusible fibers, the heat-fusible fibers being bonded to each other to have three-dimensional structure in advance of formation of the fragments; and hydrophilic fibers, the nonwoven fabric fragments and the hydrophilic fibers being blended. In this absorbent body, since the heat-fusible fibers are bonded to each other to have three-dimensional structure in advance of formation of the nonwoven fabric fragments, vacant spaces are formed inside of the absorbent body to improve the recovery after absorption of liquid. As a result, the absorbency is also improved.
- Preferably, the nonwoven fabric fragments are thermally bonded to each other after blending of the nonwoven fabric fragments and the hydrophilic fibers. In this case, since the heat-fusible fibers are bonded to each other to have three-dimensional structure in advance of formation of the nonwoven fabric fragments, the nonwoven fabric fragments can be certainly bonded to each other with relatively small calorie, thereby improving the productivity and the shape stability of the absorbent body. That is, the internal structure of the absorbent body is so stable as to maintain its original shape even after absorption of liquid.
- Preferably, the nonwoven fabric fragments consist of the heat-fusible fibers. With this, bonding of the nonwoven fabric fragments can be further facilitated.
- Preferably, the hydrophilic fibers are absorbent fibers having high water-absorbency. With this, the absorbency of the absorbent body can increase further.
- The absorbent body may further contain 5 to 95% by weight of particulates of superabsorbent polymer, and the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers may be from 2:8 to 8:2. With the superabsorbent polymer thus contained, the absorbency of the absorbent body can increase further. With the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers in the range from 2:8 to 8:2, on the other hand, well-balanced absorbency can be obtained. In detail, if the blending ratio of the nonwoven fabric fragments to the hydrophilic fibers is smaller than 2:8, compressive recovery may possibly decrease to lower absorbency. If the blending ratio is greater than 8:2, on the other hand, absorbency may possibly decrease since the hydrophilic fibers are not sufficiently present.
- Preferably, average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm. More preferably, the average dimensions are set within a range of 5 to 15 mm. With this, it becomes possible to maintain surface smoothness of product and to prevent clogging in production line.
- According to a second aspect of the present invention, there is provided an absorbent article comprising a liquid-permeable topsheet, a liquid-impermeable backsheet and an absorbent body disposed between the topsheet and the backsheet. The absorbent body comprises: fragments of nonwoven fabric including heat-fusible fibers, the heat-fusible fibers being bonded to each other to have three-dimensional structure in advance of formation of the fragments; and hydrophilic fibers, the nonwoven fabric fragments and the hydrophilic fibers being blended. In this absorbent article, since the heat-fusible fibers contained in the absorbent article are bonded to each other to have three-dimensional structure in advance of formation of the nonwoven fabric fragments, vacant spaces are formed inside of the absorbent body to improve the recovery after absorption of liquid. As a result, the absorbency is also improved in the absorbent article.
- Preferably, the nonwoven fabric fragments are thermally bonded to each other after blending of the nonwoven fabric fragments and the hydrophilic fibers. In this case, since the heat-fusible fibers are bonded to each other to have three-dimensional structure in advance of formation of the nonwoven fabric fragments, the nonwoven fabric fragments can be certainly bonded to each other with relatively small calorie, thereby improving the productivity and the shape stability of the absorbent article housing the absorbent body. That is, the internal structure of the absorbent article is so stable as to maintain its original shape even after absorption of liquid.
- Preferably, the nonwoven fabric fragments consist of the heat-fusible fibers. With this, bonding of the nonwoven fabric fragments can be further facilitated.
- Preferably, the hydrophilic fibers are absorbent fibers having high water-absorbency. With this, the absorbency of the absorbent article can increase further.
- The absorbent body may further contain 5 to 95% by weight of particulates of superabsorbent polymer, and the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers may be from 2:8 to 8:2. With the superabsorbent polymer thus contained, the absorbency of the absorbent body can increase further. With the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers in the range from 2:8 to 8:2, on the other hand, well-balanced absorbency can be obtained. In detail, if the blending ratio of the nonwoven fabric fragments to the hydrophilic fibers is smaller than 2:8, compressive recovery may possibly decrease to lower absorbency. If the blending ratio is greater than 8:2, on the other hand, absorbency may possibly decrease since the hydrophilic fibers are not sufficiently present.
- Preferably, average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm. More preferably, the average dimensions are set within a range of 5 to 15 mm. With this, it becomes possible to maintain surface smoothness of product and to prevent clogging in production line.
- According to a third aspect of the present invention, there is provided a process for manufacturing an absorbent body for use in an absorbent article, the manufacturing process comprising: forming nonwoven fabric in which constituent fibers are bonded to each other to have three-dimensional structure; breaking the nonwoven fabric into fragments; blending the nonwoven fabric fragments with hydrophilic fibers; and thermally fusion-bonding the nonwoven fabric fragments to each other. In this manufacturing process, the nonwoven fabric fragments, in which the constituent fibers have been bonded to each other to have three-dimensional structure in advance of formation of the fragments, are first prepared, mixed with the hydrophilic fibers, and then thermally bonded to each other. Therefore, the nonwoven fabric fragments can be bonded to each other with relatively small calorie, thereby improving the productivity. In addition, since the constituent fibers of the nonwoven fabric fragments have been bonded to each other to have three-dimensional structure in advance of fusion-bonding of the nonwoven fabric fragments to each other, the nonwoven fabric fragments can be certainly fusion-bonded to each other, thereby improving the shape stability of the absorbent body.
- In this manufacturing process, the absorbent body may further contain 5 to 95% by weight of particulates of superabsorbent polymer, and the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers may be from 2:8 to 8:2. With the superabsorbent polymer thus contained, the absorbency of the absorbent body can increase further. With the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers in the range from 2:8 to 8:2, on the other hand, well-balanced absorbency can be obtained. In detail, if the blending ratio of the nonwoven fabric fragments to the hydrophilic fibers is smaller than 2:8, compressive recovery may possibly decrease to lower absorbency. If the blending ratio is greater than 8:2, on the other hand, absorbency may possibly decrease since the hydrophilic fibers are not sufficiently present.
- Preferably, average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm. More preferably, the average dimensions are set within a range of 5 to 15 mm. With this, it becomes possible to maintain surface smoothness of product and to prevent clogging in production line.
- The present invention will be understood more fully from the detailed description given hereinafter and from the accompanying drawings of the preferred embodiment of the present invention, which, however, should not be taken to be limitative to the invention, but are for explanation and understanding only.
- In the drawings:
- FIG. 1 is an enlarged sectional view, schematically showing a structure of an absorbent body according to one embodiment of the invention;
- FIG. 2 is a perspective (partially cutaway) view showing a structure of an absorbent article using the absorbent body of FIG. 1; and
- FIG. 3 is a sectional view taken along line A-A of FIG. 2.
- The present invention will be discussed hereinafter in detail in terms of the preferred embodiment according to the present invention with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without these specific details. In other instance, well-known structures are not shown in detail in order to avoid unnecessary obscurity of the present invention. It should be noted that the absorbent body according to the present invention can be used for various kinds of absorbent article such as disposable diaper, pad for diaper, sanitary napkin, pet sheet, and the like.
- FIG. 1 shows a structure of an
absorbent body 10 according to one embodiment of the present invention. Theabsorbent body 10 is to be used for an absorbent article. Theabsorbent body 10 is in sheet form and comprises: fragments 12 formed from nonwoven fabric of which constituent fibers are bonded to each other to have three-dimensional structure in advance of formation of the fragments;hydrophilic fibers 14; and SAP (superabsorbent polymer) 16. The nonwoven fabric fragments 12 mainly contribute to improvement of shape stability of theabsorbent body 10. On the other hand, thehydrophilic fibers 14 and theSAP 16 mainly contribute to improvement of liquid absorbency. Here, the nonwoven fabric fragments 12 of three-dimensional structure can be obtained by breaking the nonwoven fabric into small fragments. - For the nonwoven fabric fragments12, preferably used is thermally bonded nonwoven fabric, such as spunbonded nonwoven fabric, point bonded nonwoven fabric, meltblown nonwoven fabric, through-air bonded nonwoven fabric, or the like. Among them, through-air bonded nonwoven fabric is so bulky, and therefore, it is most preferred in view of compressive recovery. As the constituent fibers forming the nonwoven fabric fragments 12, use can be made of polyolefine fibers, polyester fibers, polyamide fibers, or thick-and-thin type or side-by-side type bicomponent fibers of polyethylene/polypropylene or polyester.
- Average dimensions of the nonwoven fabric fragments12 are preferably set within a range of 3 to 25 mm, more preferably within a range of 3 to 15 mm, for example, to 5 mm. If the average dimensions of the nonwoven fabric fragments 12 are smaller than 3 mm, the compressive recovery is decreased; if greater than 25 mm, the
fragments 12 may cause clogging in production line or impair surface smoothness of products. The term “average dimension” as used herein refers to the average of the maximum dimension and the minimum dimension of each fibrous nonwoven fabric fragment. Here, at least 80% of the fibrous nonwoven fabric fragments are preferably set within the foregoing range. That is, it is not necessary to set the average dimensions of all the fragments within the range of 3 to 25 mm. As means for breaking the nonwoven fabric into thefragments 12, cutter mill method or the like can be employed. - As the
hydrophilic fibers 14, preferably used are absorbent fibers, such as pulp, cotton, rayon, acetate, or the like. As the SAP (superabsorbent polymer) 16, use can be made of any materials known in the art, for example, such as: sodium polyacrylate; acrylic acid-vinyl alcohol copolymer; sodium polyacrylate crosslinked polymer; (starch-acrylic acid) graft copolymer; (isobutylene-maleic anhydride) copolymer and saponified matter thereof; and polyasparagine acid. - The
SAP 16 may be blended into theabsorbent body 10, for example, in an amount of 5 to 95% by weight, although it is not necessarily needed for theSAP 16 to be added thereto. On the other hand, the blending ratio of the nonwoven fabric fragments 12 to thehydrophilic fibers 14 based on weight is preferably from 2:8 to 8:2. If the blending ratio is smaller than 2:8, the compressive recovery may possibly decrease to lower the absorbency. If the blending ratio is greater than 8:2, on the other hand, the absorbency may possibly decrease since the hydrophilic fibers are not sufficiently present. - Depending upon applications, the nonwoven fabric fragments12 are preferably blended in an amount of 20 to 80% by weight. In case of absorbent articles of the type which does not need superior absorbency but regards a pleasant fell to the touch as important, such as panty liners, the amount of the nonwoven fabric fragments 12 is set at 60 to 80%, for example. In case of diapers for bedridden users who are not active but discharge much urine, on the other hand, the amount of the nonwoven fabric fragments 12 is preferably set at 20 to 40%.
- It should be noted that when the
absorbent body 10 is used for absorbent articles which will be used under a condition where users move relatively vigorously, the nonwoven fabric fragments 12 are thermally bonded to each other. For manufacturing suchabsorbent body 10, nonwoven fabric in which constituent fibers are bonded to each other to have three-dimensional structure, is first prepared. Then, the nonwoven fabric is broken into the nonwoven fabric fragments 12. The nonwoven fabric fragments 12 are blended with thehydrophilic fibers 14 and theSAP 16. Thereafter, the nonwoven fabric fragments 12 are thermally fusion-bonded to each other. Thus, fusion-bonding of the nonwoven fabric fragments 12 to each other can be performed with relatively small calorie, thereby improving the productivity. In addition, because constituent fibers of eachnonwoven fabric fragment 12 have been already bonded to each other to have three-dimensional structure in advance of fusion-bonding of the nonwoven fabric fragments 12 to each other, fusion-bonding of the nonwoven fabric fragments 12 to each other can be certainly performed, thereby improving the shape stability of theabsorbent body 10. - FIG. 2 shows an
absorbent article 20 using the foregoingabsorbent body 10, which is embodied in an open-type disposable diaper. Theabsorbent article 20 is provided with a liquid-permeable topsheet 22 and a liquid-impermeable backsheet 24. More specifically, as shown in FIG. 3, water-permeable tissue papers 26 are disposed between thetopsheet 22 and theabsorbent body 10 and between thebacksheet 24 and theabsorbent body 10. Thetopsheet 22 and the water-permeable tissue paper 26 opposed to thetopsheet 22, and thebacksheet 24 and thetissue paper 26 opposed to thebacksheet 24 are bonded to each other with a hot-melt adhesive or the like, respectively. Furthermore, the upper andlower tissue papers 26 opposed to the absorbent body may also be bonded to the absorbent body with a hot-melt adhesive or the like. The hot-melt adhesive may be applied in an open pattern selected from patterns of an array of lines, dots, spirals, an array of waves, a lattice and the like. In an alternative, bonding may be directly performed by heat seal, sonic seal or the like. - For the
topsheet 22, use can be made of nonwoven fabric formed from hydrophilic fibers; apertured film, or the like. As the hydrophilic fibers, use can be made of thermoplastic fibers (e.g., polyolefine fibers, polyester fibers, polyamide fibers, or thick-and-thin type or side-by-side type bicomponent fibers of polyethylene/polypropylene or polyester) treated to be hydrophilic, or absorbent fibers (e.g., pulp, rayon, acetate or cotton). For the apertured film, preferably used is polyolefine film of polyethylene, polypropylene or the like. - For the
backsheet 24, use can be made of polyethylene film, polypropylene film, polyester film, polyurethane film or the like. In case where theabsorbent body 10 is used for wearing articles such as disposable diaper, pad, sanitary napkin or the like, the backsheet is preferred to be moisture-permeable. - Even when an external force exerts to deform the
absorbent body 10, theabsorbent article 20 thus constructed can restore to its original shape after removal of the effect of the external force. In addition, theabsorbent article 20 readily conforms to the body shape of the wearer and also exhibits superior followability to the body movement. Moreover, theabsorbent body 10 exhibits superior absorbency due to thehydrophilic fibers 14 and theSAP 16 blended therein. - As described in detail above with reference to exemplary embodiment thereof, in the absorbent article and the absorbent body used therefor, since the hydrophilic fibers are bonded to each other to have three-dimensional structure in advance of formation of the nonwoven fragments, vacant spaces are formed inside of the absorbent body to improve the recovery after absorption of liquid. As a result, the absorbency is also improved.
- In the process for manufacturing the absorbent body, on the other hand, the nonwoven fabric fragments, in which the constituent fibers have been bonded to each other to have three-dimensional structure in advance of formation of the fragments, are first prepared, mixed with the hydrophilic fibers, and then thermally bonded to each other. Therefore, the nonwoven fabric fragments can be bonded to each other with relatively small calorie, thereby improving the productivity. In addition, since the constituent fibers of the nonwoven fabric fragments have been bonded to each other to have three-dimensional structure in advance of fusion-bonding of the nonwoven fabric fragments to each other, the nonwoven fabric fragments can be certainly fusion-bonded to each other, thereby improving the shape stability of the absorbent body.
- Although the present invention has been illustrated and described with respect to exemplary embodiment thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omission and additions may be made therein and thereto, without departing from the spirit and scope of the present invention. Therefore, the present invention should not be understood as limited to the specific embodiment set out above but to include all possible embodiments which can be embodied within a scope encompassed and equivalent thereof with respect to the feature set out in the appended claims.
Claims (18)
1. An absorbent body for use in an absorbent article, the absorbent body comprising: fragments of nonwoven fabric including heat-fusible fibers, the heat-fusible fibers being bonded to each other to have three-dimensional structure in advance of formation of the fragments; and hydrophilic fibers, the nonwoven fabric fragments and the hydrophilic fibers being blended.
2. An absorbent body as set forth in claim 1 , wherein the nonwoven fabric fragments are thermally bonded to each other after blending of the nonwoven fabric fragments and the hydrophilic fibers.
3. An absorbent body as set forth in claim 1 , wherein the nonwoven fabric fragments consist of the heat-fusible fibers.
4. An absorbent body as set forth in claim 1 , wherein the hydrophilic fibers are absorbent fibers having high water-absorbency.
5. An absorbent body as set forth in claim 1 , which further contains 5 to 95% by weight of particulates of superabsorbent polymer, wherein the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers is from 2:8 to 8:2.
6. An absorbent body as set forth in claim 1 , wherein average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm.
7. An absorbent body as set forth in claim 6 , wherein the average dimensions are set within a range of 5 to 15 mm.
8. An absorbent article comprising a liquid-permeable topsheet, a liquid-impermeable backsheet and an absorbent body disposed between the topsheet and the backsheet,
the absorbent body comprising: fragments of nonwoven fabric including heat-fusible fibers, the heat-fusible fibers being bonded to each other to have three-dimensional structure in advance of formation of the fragments; and hydrophilic fibers, the nonwoven fabric fragments and the hydrophilic fibers being blended.
9. An absorbent article as set forth in claim 8 , wherein the nonwoven fabric fragments are thermally bonded to each other after blending of the nonwoven fabric fragments and the hydrophilic fibers.
10. An absorbent article as set forth in claim 8 , wherein the nonwoven fabric fragments consist of the heat-fusible fibers.
11. An absorbent article as set forth in claim 8 , wherein the hydrophilic fibers are absorbent fibers having high water-absorbency.
12. An absorbent article as set forth in claim 8 , wherein the absorbent body further contains 5 to 95% by weight of particulates of superabsorbent polymer, and the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers is from 2:8 to 8:2.
13. An absorbent article as set forth in claim 8 , wherein average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm.
14. An absorbent article as set forth in claim 13 , wherein the average dimensions are set within a range of 5 to 15 mm.
15. A process for manufacturing an absorbent body for use in an absorbent article, the manufacturing process comprising:
forming nonwoven fabric in which constituent fibers are bonded to each other to have three-dimensional structure;
breaking the nonwoven fabric into fragments;
blending the nonwoven fabric fragments with hydrophilic fibers; and
thermally fusion-bonding the nonwoven fabric fragments to each other.
16. A manufacturing process as set forth in claim 15 , wherein the absorbent body further contains 5 to 95% by weight of particulates of superabsorbent polymer, and the blending weight ratio of the nonwoven fabric fragments to the hydrophilic fibers is from 2:8 to 8:2.
17. A manufacturing process as set forth in claim 15 , wherein average dimensions of the nonwoven fabric fragments are set within a range of 3 to 25 mm.
18. A manufacturing process as set forth in claim 17 , wherein the average dimensions are set within a range of 5 to 15 mm.
Priority Applications (1)
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US12/725,107 US8182623B2 (en) | 2001-04-06 | 2010-03-16 | Absorbent article, absorbent body for absorbent article, and manufaturing process therefor |
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JP2001-108263 | 2001-04-06 | ||
JP2001108263A JP3916205B2 (en) | 2001-04-06 | 2001-04-06 | Absorbent article, absorbent body for absorbent article, and method for producing the same |
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US12/725,107 Division US8182623B2 (en) | 2001-04-06 | 2010-03-16 | Absorbent article, absorbent body for absorbent article, and manufaturing process therefor |
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US12/725,107 Expired - Fee Related US8182623B2 (en) | 2001-04-06 | 2010-03-16 | Absorbent article, absorbent body for absorbent article, and manufaturing process therefor |
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US12/725,107 Expired - Fee Related US8182623B2 (en) | 2001-04-06 | 2010-03-16 | Absorbent article, absorbent body for absorbent article, and manufaturing process therefor |
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AT (1) | ATE406149T1 (en) |
DE (1) | DE60228518D1 (en) |
SG (1) | SG105542A1 (en) |
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CN107242938A (en) * | 2017-07-07 | 2017-10-13 | 陈建辉 | Water-absorption core body and its preparation method and application |
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EP1247509A2 (en) | 2002-10-09 |
KR20020079471A (en) | 2002-10-19 |
TW546134B (en) | 2003-08-11 |
ATE406149T1 (en) | 2008-09-15 |
JP2002301105A (en) | 2002-10-15 |
JP3916205B2 (en) | 2007-05-16 |
EP1247509B1 (en) | 2008-08-27 |
EP1247509A3 (en) | 2005-10-12 |
US8182623B2 (en) | 2012-05-22 |
US20100174259A1 (en) | 2010-07-08 |
SG105542A1 (en) | 2004-08-27 |
DE60228518D1 (en) | 2008-10-09 |
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